Network interface device module providing sealed customer-accessible test port

ABSTRACT

A subscriber module (40) for a network interface device (10) having a jack (100) defining a plug-receiving cavity (102) thereinto, and having a plug (50) insertable into the jack. The plug includes a plurality of interconnecting contacts (56) disposed at a mating end (58) thereof, and the jack includes first and second contacts (106,112) secured within the plug-receiving cavity in spaced-apart disconnected pairs. Insertion of plug (50) into jack (100) moves interconnecting contacts (56) between associated ones of first and second contacts (106,112) to electrically interconnect them, completing otherwise unconnected circuits between the distribution cable and the subscriber premise wiring. Preferably plug (50) includes a sealing member (74) therearound to seal the mating interface when plug (50) is inserted into jack (100). Conductors (36) of the premise wiring are terminatable by insulation displacement techniques to terminals (164) using a stuffer cap (152), with terminals (164) connected to second contacts (112) by traces of circuit board (170 ) mounted within module (40), while first contacts (106) are electrically connected by other traces of board (170) to conductors (38) connected to the distribution cable.

FIELD OF THE INVENTION

The present invention is directed to telephone network interface devicesand more particularly to customer-accessible modules thereof.

BACKGROUND OF THE INVENTION

Network interface devices provide limited access by a subscriber orcustomer for testing by the subscriber of the subscriber premiseswiring, at a telephone junction box where the subscriber premises wiringis connected to the telephone company distribution cable. Such junctionboxes are also fully accessible to service personnel of the telephonecompany after installation. One such network interface device isdisclosed in U.S. Pat. No. 4,979,209 for a plurality of subscribers,wherein an enclosure includes a primary lid extending over the entireenclosure and securable by service personnel, and a secondary lid overthe subscriber-accessible portion of the enclosure securable by thesubscribers; such enclosures commonly provide access to thesubscriber-accessible portion by service personnel but thesubscriber-accessible portion remains secured against unauthorizedpersons. Individual modules within the subscriber-accessible portion aredisclosed to include individual security covers such that eachsubscriber module is secured against access by the other subscribers.

The individual subscriber module includes a test port or jackelectrically connected to both the premises wiring and thesubscriber-dedicated wiring of the telephone company's distributioncable, enabling the subscriber to remove the port cover and insert theplug of a telephone or other test device to discover the location of afault disrupting the subscriber's service. Successful connection of thetelephone or test device indicates that the fault lies in the premiseswiring and thus is the responsibility of the subscriber, whereas anunsuccessful connection of the telephone or test device indicates thatthe fault lies in the wiring of the telephone company. The performanceof such testing by the subscriber enables the subscriber to firstdetermine the location of the fault prior to arranging with thetelephone company for a service call, thus saving subscriber the expenseof a telephone company service call when the fault lies in the premiseswiring.

Prior art test ports have been of the type including a conventionaltelephone plug connector having an array of two or four contacts matablewith contacts in the jack, with the plug's contacts affixed to conductorwires extending from the plug and connected to the premises wiring.Deterioration of the conductor wires extending from the plug hasfrequently occurred from removal and replacement of the plug from andinto the jack, or from exposure of the conductors to inadvertent damageby tools during installation or servicing or testing or otherwise.Occasionally problems of exposure of the contacts in the jack tomoisture have also occurred, necessitating service and repair to thesubscriber module.

It is desired to provide a subscriber module that eliminates thesusceptibility of conductor wires to damage, and the corrosion ofcontact surfaces in the jack by moisture.

SUMMARY OF THE INVENTION

In the present invention, a subscriber module includes a plug having anarray of interconnecting contacts along the mating face that are notconnected to conductor wires, but in essence is a shunt. The plug ispreferably secured to the module by a nonconducting lanyard such as astrand of high strength flexible plastic, and includes a manuallygrippable portion extending from the plug at the end opposite the matingface, for manipulation of the plug during removal from the jack andreplacement thereinto. A sealing member of elastomeric material isprovided in a groove around the plug that deformingly engages side wallsof the jack when the plug is fully inserted into the jack, thusproviding assured sealing of the mating interface between the plug andjack.

The jack provides spaced pairs of contacts at the mating face associatedwith each contact of the plug array and that are by themselves notelectrically joined, defining an intentional gap in the connectionbetween the distribution cable wiring and the premises wiring, with onesof each contacts of the several pairs being electrically connected toconductors of the distribution cable and others of each contacts of theseveral pairs being electrically connected to conductors of the premiseswiring, all completely housed within the module. Upon the plug beingsecured in the test port or jack, its interconnecting contacts providean assured electrical connection between the otherwise unconnectedassociated contacts of the pairs of jack contacts and enabling telephoneservice to be established between the distribution cable and thepremises wiring.

It is an objective of the present invention to provide a subscriber testport of a subscriber module that seals the mating interface againstmoisture when a test is not being conducted.

It is also an objective to provide a plug that does not requireconductors that are susceptible to damage by being exposed or requiremanipulation during removal and reinsertion of the plug.

It is a further objective to provide a subscriber module that includesthe capability of placement of testing or other components sealed withinthe module without requiring modification to the module housing.

An embodiment of the present invention will now be described by way ofexample with reference to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an isometric view of a network interface device with theprimary lid closed and the secondary lid opened illustrating thesubscriber portion containing an array of subscriber modules containingthe present invention;

FIG. 2 is an isometric view of a subscriber module with the plug removedfrom the jack and showing conductors extending to the module frompremise wiring and from a distribution cable;

FIG. 3 is a cross-sectional view of the plug fully inserted within thejack and an interconnecting contact interconnecting a pair of contactstherein; and

FIG. 4 is an isometric view of the plug in place within the jack and astuffer cap lifted to its open position for termination of subscriberwiring; and

FIG. 5 is an isometric exploded view of the module of FIGS. 1 to 4showing the circuit board with contacts and terminals mounted thereto.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

In FIG. 1 is shown network interface device 10 comprising an enclosure12 having a subscriber portion 14 and a telephone company portion 16,with the enclosure 12 having a primary lid 18 secured at lock 20 toprevent access by non-service personnel to portion 16. A pair ofdistribution cables 22 are shown extending from portion 16. Secondarylid 30 is shown in the opened position and includes a lock 32 for beingsecured to primary lid 18 when closed, with an array of subscribermodules 40 mounted within subscriber portion 14. Individual subscribercables 34 are shown extending from subscriber portion 14 of enclosure 12that extend into the premises of the customer or subscriber, and theconductors 36 of each subscriber cable are electrically connected tocircuits within an associated subscriber module 40 mounted in subscriberportion 14 of enclosure 12.

Security covers 42 are seen in their open positions and are pivotallymounted at hinges 44 to respective modules 40 to be rotated to a closedposition and thereafter locked if desired by the respective subscriberat lock locations 46, such as by using conventional Size 10 padlocks.

Each module 40 includes a cable face 48 for connection of ends ofconductors 36 of subscriber cables 34 to terminals within the module,and also provides electrical connections to conductors 38 extending totelephone company portion 16 for connection to conductors of adistribution cable 22. A plug 50 is affixed to module 40 such as by alanyard 52 and includes a tab portion 54 extending upwardly from themodule enabling manual gripping for removal of the plug from itsrespective jack.

Referring now to FIGS. 2 and 3, plug 50 is shown to have a polarizedmating end 58 as is conventional with plug connectors in use in thetelephone industry to connect telephones to premise wiring atconventional jacks having complementarily shaped plug-receivingcavities. Plug 50 is formed of dielectric material such as thermoplasticresin, and is seen to have four interconnecting contacts 56 affixed tomating face 58 at a mating end of the plug and including contactsections 60,62 along side surfaces 64,66 connected by a body section 68.Interconnecting contacts 56 are seen disposed within correspondinggrooves 70 secured therein such as by barbs 72 at ends of contactsections 60,62. Spaced rearwardly from mating face 58 is an elastomericsealing member 74 such as an 0-ring seated in a groove 76 extendingaround intermediate section 78. Plug 50 also includes an enlargeddiameter cover flange 80 to traverse and close the opening to jack 100.

Jack 100 is defined by dielectric housing 98 of module 40 and includes aplug-receiving cavity 102 with a mating interface adjacent bottom 104 ofthe cavity. First contacts 106 are arrayed in respective grooves 108along a first side 110 and second contacts 112 in grooves 114 along asecond side 116, all having cantilever beam contact arms 118,120associated with contact sections 60,62 of interconnecting contacts 56 ofplug 50, extending toward cavity bottom 104 at angles intoplug-receiving cavity 102 in opposed pairs to become electricallyengaged by interconnecting contacts 56 and thus become interconnected tocomplete respective circuits upon full insertion of plug 50 into cavity102. Annular surface portion 122 of enlarged diameter cavity portion 124is engaged by sealing member 74 of plug 50 upon full insertion to definean environmental seal protecting the mating interface at the bottom ofcavity 102. A friction fit of O-ring 74 against surface portion 122 issufficient to retain plug 50 within jack 100 without a latchingarrangement. Plug-receiving cavity 102 and contacts 106,112 thereindefine a test port for receipt of a plug for testing of the circuits ofthe subscriber premise wiring and the distribution cable, and with plug50 fully inserted thereinto is sealed.

First contacts 106 include posts 126 extending through holes of circuitboard 170 for soldering to associated traces (not shown) of board 170,and second contacts 110 similarly include posts 128 in holes of board170 and are soldered to other traces of board 170.

In FIG. 4, wire termination section 150 is seen to include a stuffer cap152 disposed within a slot 154 and movable vertically between apretermination or open position, and a termination or closed position,and that includes a grippable section 156 to be manipulated. Stuffer cap152 is shown to have four wire-receiving sections 158 for receiptthereinto of ends of respective conductors 36 when in the open position,whereafter movement to the closed position moves the wires into supportslots 160 of housing 98 and into insulation displacement slots 162 ofterminals 164 in a manner generally conventionally known. Terminals 164include post sections 166 and are mounted on a circuit board 170traversing the bottom of module 40 (best seen in FIG. 5) and areelectrically connected to respective traces thereon.

On circuit board 170, the traces from terminals 164 extend to respectiveones of second contacts 112 of jack 100 and electrically connectedthereto, thus completing circuits from the second contacts 112 toconductors 36 of the subscriber cable 34. Additional traces extend fromfirst terminals 106 to terminations with conductors 38 that extend intotelephone company portion 16 of network interface device 10 forconnection to distribution cables 22. Preferably probe contacts 172(FIG. 5) have post sections and are mounted onto circuit board 170joined to selected traces thereof and extending to exposed contactsections 174 within recesses 176 along accessible surface 178 of module40 for testing by service personnel.

It is desired that conductors 38 are connected to associated conductorsof the cable in the telephone company portion 16 of the networkinterface device, by means of protector modules (not shown) such as aredisclosed in U.S. Pat. No. 5,317,474. Such protector modules establishprotection against surges of voltage and current along the circuits thusprotecting equipment from damage.

Preferably upon assembly of module 40 with contacts 106,112 andterminals 164 mounted onto circuit board 170, and termination ofconductors 38 to traces of circuit board 170, potting material 180 isdisposed along the outwardly facing surface of the circuit board withinboard-receiving recess 182 into the bottom face of module 40, thusenvironmentally sealing the electrical connections within module 40.

One aspect of the present invention is circuit board 170 within asubscriber module 40, that enables utilization of additional electricalor electronic components within the module, such as a maintenance testunit (not shown), or a half-ringer enabling computer polling ofsubscriber lines to the module for fault-free verification even in theabsence of a telephone unit properly connected to premise wiring withinthe premises.

Variations and modifications can be devised to the embodiment of theinvention disclosed herein, that are within the spirit of the inventionand the scope of the claims.

We claim:
 1. A subscriber module for a network interface device havingelectrical connections between conductors of subscriber premise wiringand conductors of a distribution cable and enabling subscriber testingof the subscriber premise wiring, comprising:a dielectric housingdefining a jack having a plug-receiving cavity into an accessible facethereof and having a mating face therewithin, first and second contactsmounted adjacent said mating face in associated opposed pairs andincluding respective contact sections exposed therealong in saidplug-receiving cavity; said dielectric housing having a wire terminationsection including terminals exposed for termination to respectiveconductors of subscriber premise wiring, and associated stuffer capsactuable to terminate said conductors to said terminals; a circuit boardsecured within said dielectric housing and including traces electricallyconnected to said first and second contacts proximate said jack, saidtraces connecting said first contacts to conductors at leastelectrically connected to associated conductors of said distributioncable and connecting said second contacts to respective said terminalsproximate said wire termination section; and a plug complementary tosaid jack and insertable and latchable therewithin, said plug includinginterconnecting contacts mounted to a mating face thereof associatedwith said mating face of said jack, each said interconnecting contactbeing electrically isolated from other conductive media and including abody section joining first and second contact sections exposed to engagesaid first and second contacts of said jack upon full insertion of saidplug into said plug-receiving cavity thereof, thereby interconnectingsaid first contacts with associated said second contacts and completingotherwise unconnected respective circuits between conductors of saidsubscriber premise wiring and associated conductors of said distributioncable when said plug is fully inserted in said jack.
 2. The subscribermodule as set forth in claim 1 wherein said plug further includes asealing member seated in a groove around an intermediate section of saidplug spaced from said mating end, engaging and compressed by acorresponding surface portion around said plug-receiving cavity forsealing said mating interface when said plug is fully inserted into saidjack.
 3. The subscriber module as set forth in claim 1 wherein said plugincludes a manually grippable tab extending outwardly therefrom enablinggripping thereof for removal of said plug from said jack during testing.4. The subscriber module as set forth in claim 1 wherein said plug issecured to said module by a lanyard.
 5. The subscriber module as setforth in claim 1 wherein each said stuffer cap includes a manuallygrippable tab extending outwardly therefrom enabling gripping thereoffor movement of said stuffer cap between said open and closed positions.6. The subscriber module as set forth in claim 1 wherein each saidstuffer cap is secured in a respective said slot when in said openposition.
 7. The subscriber module as set forth in claim 1 furtherincluding probe contacts mounted onto said circuit board andelectrically connected to selected said traces and having ends exposedalong a top surface enabling testing by service personnel.
 8. Thesubscriber module as set forth in claim 1 wherein potting material isdisposed along a bottom face of said dielectric housing upon securingsaid circuit board therewithin thereby sealing said electricalterminations within the module.
 9. The subscriber module as set forth inclaim 1 wherein each said first and second contact includes an outwardlydeflectable contact section disposed at an angle into saidplug-receiving cavity prior to engagement and deflection outwardly by acorresponding said contact section of a corresponding saidinterconnecting contact of said plug.
 10. The subscriber module as setforth in claim 9 wherein each said interconnecting contact is disposedwithin a respective groove of said mating end of said plug, with saidbody section thereof traversing a front surface of said mating end andeach said contact section extending along a side surface of said matingend.
 11. A test port of a subscriber module of a network interfacedevice wherein conductors of distribution cable are to be connected toconductors of premise wiring of a subscriber of telephone service,comprising:a jack including a plug-receiving cavity and an array ofcontact members exposed for engagement at a mating interface within saidplug-receiving cavity; a plug member insertable into and removable fromsaid plug-receiving cavity and including an array of contact membersengageable with said jack contact members, with said plug memberremovable from said jack to permit insertion of another plug member fortesting; a sealing member disposed continuously about an intermediatesection of said plug member spaced from a mating end portion thereof;and an enlarged portion of said plug-receiving cavity adjacent anentrance thereto having side wall surfaces engageable with said sealingmember continuously about said enlarged portion, whereby the matinginterface of said jack and plug member is sealed when the plug member isfully inserted into the jack.
 12. The test port as set forth in claim 11wherein said sealing member is an annular formation of compressiblematerial having an outermost diameter larger than the inner diameter ofsaid enlarged portion of said plug-receiving cavity adjacent thereto,and compressible radially inwardly thereby.
 13. The test port as setforth in claim 12 wherein said sealing member is a a separate ring ofcompressible material seated within a groove in said intermediateportion of said plug member.
 14. A test port of a subscriber module of anetwork interface device wherein conductors of distribution cable areconnected to conductors of premise wiring of a subscriber of telephoneservice, comprising:a jack including a plug-receiving cavity and anarray of contact members exposed for engagement at a mating interfacewithin said plug-receiving cavity; a plug member insertable into andremovable from said plug-receiving cavity and including an array ofcontact members exposed to be engageable with said jack contact members,with said plug member removable from said jack to permit insertion ofanother plug member for testing; said contact members of said jack arearranged in opposing pairs spaced apart and electrically unconnectedwhen said plug member is unmated from said jack, one contact member ofeach said pair being connected to a circuit extending to a distributioncable and the other contact member of each said pair being connected toa circuit extending to premise wiring of a subscriber of telephoneservice; and said contact members of said plug member being unconnectedto any circuit when said plug member is unmated from said jack, eachsaid contact member including contact sections associated with said oneand a said other of an associated pair of said contact members of saidjack, defining interconnecting contacts adapted to interconnect saidones and others of said pairs of contact members of said jack when saidplug member is fully inserted into said jack, thus interconnectingotherwise unconnected ones of said conductors of said distribution cableand associated conductors of said premise wiring.